Methods of magnetic conveyor support

ABSTRACT

Apparatuses designed to provide support to a conveyor belt in a new manner. In a first illustrative embodiment, a conveyor belt is supported by a number of magnets. A first set of magnets are disposed on the edges of the conveyor belt, and a second set of magnets are disposed on a support apparatus for the conveyor belt. The first and second sets of magnets interact to create repulsive forces that provide both lateral and vertical support to the conveyor belt. Tension provided by the lateral forces can help the belt move smoothly and with less wear than the support provided by existing support idlers.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of co-pending U.S. application Ser.No. 11/616,752, filed Dec. 27, 2006; which is a continuation of U.S.application Ser. No. 11/263,690, filed Nov. 1, 2005, now U.S. Pat. No.7,159,708; which is a divisional of U.S. application Ser. No.10/732,718, filed Dec. 10, 2003, now U.S. Pat. No. 6,971,507; the entiredisclosures of which are incorporated herein by reference.

FIELD

The present invention is related to the field of materials conveyance.More particularly, the present invention relates to the field ofconveyer devices.

BACKGROUND

Conveyor belts are used to move materials in a wide variety ofindustries and environments. Some such conveyor belts are used, forexample, in moving ore within a mine, gravel or rocks within a quarry,and in a variety of industrial applications where bulk materials aremoved.

FIG. 1 illustrates a prior art conveyor. The conveyor includes aconveyor framework 2 which may be made, for example, using channel,angle-iron, trusswork, or a variety of other configurations. A conveyorbelt 4 is supported by support idler frames 6 which include a number ofsupport idler rollers 8. Driving force may be applied by any number ofmethods/apparatuses, including, for example, creating a turning force atthe rollers shown on the end of the framework 2, or by application offorce using magnets on the conveyor belt 4 itself which interact withstators placed relative the edges of the conveyor belt 4.

FIG. 2 shows a closer, cut-away view of a prior art conveyor,highlighting the conveyor belt 4, idler support 6, and idler rollers 8.As shown, the idler rollers 8 are angled with respect to one anothersuch that the conveyor belt 4 forms a trough in which a material to beconveyed rests during transport. The idler supports 6 are securedrelative the conveyor framework 2. There is a slight sag between therollers 8, and it can be seen that the conveyor belt 4 does not passsmoothly over the rollers 8, instead being shaped thereby with slightangular form.

The conveyor belt 4 is typically constructed as a relatively flat,flexible member having a first end and a second end, where the ends aresecured together to create a loop by the use of a securing apparatus. Ina simplest form, the conveyor belt 4 has two ends coupled together byinteracting teeth or interleaved loops, where a wire, for example, ispassed through the interleaved loops to secure the first end of theconveyor belt 4 to the second end of the conveyor belt 4. Other forms,such as vulcanized “endless” belts may also be used. Any number ofindividual sections may be pieced together in this or another suitablemanner to build the conveyor belt 4.

One of the limitations of such prior art conveyor support designs isthat the supportive force of the rollers 8 causes localized strain onthe conveyor belt 4, wearing the conveyor belt 4. Further, the rollers 8are subject to wear and degradation, and require periodic replacement.The rollers 8 include internal bearings that occasionally wear out, andwith the large number of moving parts, the overall system is subject tofailure in harsh environments.

SUMMARY

The present invention, in an illustrative embodiment, includesapparatuses designed to provide support to a conveyor belt in a newmanner. In a first illustrative embodiment, a conveyor belt is supportedby a number of magnets. A first set of magnets are disposed on the edgesof the conveyor belt, and a second set of magnets are disposed on asupport apparatus for the conveyor belt. The first and second sets ofmagnets interact to create repulsive forces that provide both lateraland vertical force to the conveyor belt.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an illustrative prior art conveyor;

FIG. 2 is a cutaway view highlighting a portion of the illustrativeprior art conveyor of FIG. 1;

FIG. 3 is a perspective view of a first embodiment of a magneticallysupported conveyor system;

FIG. 4 is a section view of an illustrative embodiment showing greaterdetail of the supporting framework for a magnetically supported conveyorsystem;

FIG. 5 is a cross-sectional view of an illustrative support framework;

FIG. 6 is a cross-sectional view of another illustrative supportframework;

FIG. 7 is a cross-sectional view of yet another illustrative supportframework;

FIG. 8 illustrates in detail a magnetic layout for a magneticallysupported conveyor system;

FIG. 9 illustrates in detail another magnetic layout for a magneticallysupported conveyor system;

FIG. 10 illustrates a rectangular magnetic layout for a magneticallysupported conveyor system;

FIG. 11 shows, in side view, a portion of a magnetically supportedconveyor system;

FIG. 12 is a cross-sectional view of another illustrative supportframework; and

FIG. 13 is a side view of another illustrative conveyor system.

DETAILED DESCRIPTION

The following detailed description should be read with reference to thedrawings. The drawings, which are not necessarily to scale, depictillustrative embodiments and are not intended to limit the scope of theinvention.

FIG. 3 is a perspective view of a first embodiment of a magneticallysupported conveyor system. The system includes a conveyor framework 52that is used with a conveyor belt 54. The system includes tensionmembers 60 and several support arms 62 that are secured to the conveyorframework 52 by several support pivot mounts 64. Several upper pivotmounts 66 are also included.

The conveyor belt 54 is at least partly supported by the use of magneticforces. In particular, a number of outer magnet housings 70 are securedto the conveyor belt 54. The conveyor belt 54 is then suspended betweentwo inner magnet housings 72. As illustrated in greater detail below,the outer magnet housings 70 and inner magnet housings 72 interactmagnetically. Repulsive forces between the outer magnet housings 70 andinner magnet housings 72 support the conveyor belt 54.

FIG. 4 is a section view of an illustrative embodiment showing greaterdetail of the supporting framework for a magnetically supported conveyorsystem. The conveyor framework 52 is secured by a lower pivot mount 68to the tension member 60, which is in turn secured to the support arm 62by the upper pivot mount 66. The support arm 62 is also secured to theconveyor framework by support pivot mounts 64.

As can be seen, the outer magnet housings 70 wrap around the innermagnet housing 72 so that both lateral and vertical support is providedto the conveyor belt 54. The conveyor belt 54 is held in position underlateral tension. The weight of whatever material is carried the conveyorbelt 54 will cause the conveyor belt 54 to sag in the middle. As theconveyor belt 54 sags, more material can be carried by the conveyor upto a point, however, too much sag can reduce capacity and causeexcessive wear on the conveyor belt 54. To prevent too much sag fromoccurring, tension members 60 are provided between the support arms 62.If the conveyor belt 54 is empty, less wear on the conveyor belt 54occurs when it runs flat, so the tension members 60 are also adapted tocause the conveyor belt 54 to run flat when empty, yet allow some sag tooccur as the conveyor belt 54 is loaded. The tension members 60 mayinclude a stop preventing too much sag from occurring, for example, tokeep the conveyor belt 54 from coming into contact with the tensionmembers 60. If desired or necessary, additional support devices may beused in conjunction with the magnetic support provided by the magnethousings 70, 72. The several pivot mounts 64, 66, 68 allow the conveyorbelt 54 to go from a sagging configuration to a flat position (and thereverse) smoothly and easily.

FIG. 5 is a cross-sectional view of an illustrative support framework.The cross section shows how the tension members 60 cross from the lowerpivot mounts 68 to the upper pivot mounts 66 to provide lateral supportto the support arms 62. The support pivot mounts 64 allow the supportarms 62 to move with respect to the conveyor framework 52, allowing theconveyor belt 54 to have lateral flexibility.

Also illustrated is how the outer magnet housing 70 at least partlysurrounds the inner magnet housing 72. The outer magnet housing 70contains outer magnets 76, which interact with inner magnets 74contained by the inner magnet housing 72. The outer magnets 76 are allaligned in similar polarity, as are the inner magnets 74, such that theouter magnets 76 collectively repel the inner magnets 74. The conveyorbelt 54 thus moves on a cushion of air with decreased wear and friction.

While the preferred embodiments of the present invention include magnets74, 76 that create a cushion of air between the inner and outerhousings, other configurations are also contemplated. For example,frictional contact between the inner and outer housings may be allowedin some embodiments. If desired a lubricant (wet or dry) may be providedbetween the inner and outer housings to make movement with contacteasier.

Additionally, the magnets 74, 76 may provide primary or supplementalsupport to a conveyor belt. For example, if desired, the magnets 74, 76may be sufficient to provide guiding forces to a belt, wherein themagnets 74, 76 and tension members 60 are sufficient to keep the beltrelatively flat while the belt is running empty, but when the belt isloaded the belt is allowed to deform and move generally as shown in FIG.1, with rollers disposed longitudinally between the tension members. Byallowing the belt to run relatively flat while unloaded, friction andwear are reduced, while rollers may be provided to give additionalsupport when the belt is heavily loaded.

In several embodiments additional support devices may be provided aswell. For example, an impact cradle or bed such as an impact slider bedmay be provided beneath the belt 54 at a location corresponding to ahopper or loading area. The impact slider bed may include, for example,a slippery hard plastic upper layer over a cushioned layer. One exampleimpact slider bed includes a number of elongate members that runlongitudinally beneath a portion of the belt 54, each elongate memberhaving at least two layers, with the upper layer being a slipperyplastic about ⅓ the thickness of the member, and a lower layer made upof a relatively soft, cushioning rubber that covers approximately ⅔ ofthe thickness of the member. If desired, a spring or rigid support, suchas a piece of iron or steel, may hold up the elongate members.

FIG. 6 is a cross-sectional view of another illustrative supportframework. Again, the tension members 60 are coupled to the support legs62 and conveyor framework 52 using upper and lower pivot mounts 66, 68.The support legs 62 themselves are coupled to the conveyor framework bythe support pivot mounts 64. The main difference from FIG. 5 to FIG. 6is in the shape of the outer magnet housing 70′ and inner magnet housing72′. Rather than a curved shape (as shown by the magnet housings 70, 72in FIG. 5), the magnet housings 70′, 72′ in FIG. 6 are rectangular. Byusing the rectangular shape, the inner magnets 74′ may be disposeddifferently, for example, the upper magnet of the inner magnets 74′ mayhave a N/S polarity where the N pole is up, and the lower magnet mayhave the same alignment, so that the upper and lower magnets of theinner magnet attract one another and hold each other in place, yet repelthe outer magnets 76′.

FIG. 7 is a cross-sectional view of yet another illustrative supportframework. A conveyor framework 152 is used to support a conveyor belt154 as follows. Support arms 162 are secured to the conveyor frameworkby support pivot mounts 164. A tension member 160 is coupled to thesupport arms 162 using arm pivot mounts 166. The tension member 160 isconfigured to push the support arms 162 apart, keeping the conveyor belt154 under tension. The tension member 160 configured as shown simplifiesthe overall design, however, as illustrated, the conveyor belt 154 isnot allowed to sag as far as it otherwise might, since the tensionmember 160 is in the way.

The conveyor belt 154 is coupled to the support arms 162 by the use ofan outer magnet housing 170 that is disposed about an inner magnethousing 172. The repulsive magnetic forces between the inner magnets 174and outer magnets 176 creates an air gap that allows the conveyor belt154 to move without significant friction caused either by support alongits edges or friction creating by passage over idler rollers.

FIG. 8 illustrates in detail a magnetic layout for a magneticallysupported conveyor system. The configuration corresponds to thatillustrated in FIG. 5. The tension member 60 pushes the arm 62 outwardthrough its connection to the upper pivot mount 66. In turn, the armtransmits both vertical and lateral forces to the inner magnet housing72 containing a number of inner magnets 74. Preferably, each of theinner magnets 74 is orientated with the same field polarity facingoutside. The outer magnet housing 70 contains several outer magnets 76,which preferably are orientated to each have the same field polarityfacing inside. The field polarity facing inside for the outer magnets 76is preferably the same as the field polarity facing outside for theinner magnets 74, such that the outer magnets 76 and inner magnets 74repel one another.

FIG. 9 illustrates in detail another magnetic layout for a magneticallysupported conveyor system. The inner magnets 74 comprise a singlemagnet, and the outer magnets 76 are also a single magnet. If desired,one or both of the magnets may be an electro-magnet that is coupled to asource of electricity such that, when the electricity is on, themagnetic field generated by at least one of the magnets 74, 76 isboosted. Then, if desired, the electricity could be cut off when thebelt 54 is not moving, reducing the resting tension on the belt 54.

FIG. 10 illustrates a rectangular magnetic layout for a magneticallysupported conveyor system. The outer magnet housing 70′ is shaped topreserve an air cushion around the inner magnet housing 72′. The innermagnets 74′ are oriented and disposed to provide a repulsive force withrespect to the outer magnets 76′.

FIG. 11 shows, in side view, a portion of a magnetically supportedconveyor system. The system may include a number of outer housingstructures 70 disposed about an inner housing structure 72 to supportthe conveyor belt 54. The conveyor belt 54 is supported over a conveyorframework 52 by the use of several support arms 62 that may be spaced oralternated as shown. The support arms 62 are secured between theconveyor framework 52 and the conveyor belt 54 by support pivot mounts64. Tension members 60 may attach to the support arms 62 as noted above.

The conveyor belt 54 may be motivated by any suitable mechanism ordevice. Pulley and/or roller systems, along with geared devices havingteeth that engage the conveyor belt 54 may be used. Several magnet andstator systems may also be used, for example.

FIG. 12 is a cross-sectional view of another illustrative supportframework. The support framework supports a conveyor belt 100 usingouter magnetic housings 102 and inner magnetic housings 104. Thehousings 102, 104 may be as outlined above. The support arms 106 aretensioned, laterally, by a tension member 108. Rather than twoside-by-side frame members having a number of cross members therebetween(such a support framework would be used with several of the aboveembodiments), the illustrative framework in FIG. 12 makes use of asingle central member 110. Because the support arms 106 angle outwardwith respect to the central member 110, the force of gravity createstension across the conveyor belt 100. As such the conveyor belt 100tends to run flat when unloaded.

The tension member 108 may provide pushing forces between the supportarms 106 when the conveyor belt 100 is heavily loaded. For example, ifthe conveyor belt 100 is heavily loaded, troughing in the middle willtend to pull the support arms 106 together, so the tension member 108may provide a pushing force to prevent over-troughing of the conveyorbelt 100.

FIG. 13 is a side view of another illustrative conveyor system. Thesystem is similar to that shown in FIG. 11, with a first magneticsupport structure shown generally at 150 for belt 152, and a secondmagnetic support structure shown generally at 154. Between the magneticsupport structures is a roller-type structure, as shown generally at156.

Those skilled in the art will recognize that the present invention maybe manifested in a variety of forms other than the specific embodimentsdescribed and contemplated herein. Accordingly, departures in form anddetail may be made without departing from the scope and spirit of thepresent invention as described in the appended claims.

1. A material conveyance apparatus comprising: a belt extending in alongitudinal direction, the belt having a first side edge including oneor more magnets and a second side edge including one or more magnets; aframework for supporting the belt, the framework including: a centralmember extending in the longitudinal direction; a first support armextending outward from the central member toward the first side edge ofthe belt; and a second support arm extending outward from the centralmember toward the second side edge of the belt; wherein the one or moremagnets of the first side edge provide a repulsive force repelling thefirst side edge away from the first support arm; and wherein the one ormore magnets of the second side edge provide a repulsive force repellingthe second side edge away from the second support arm.
 2. The materialconveyance apparatus of claim 1, wherein a lateral direction is definedbetween the first side edge and the second side edge of the belt,wherein the repulsive force provided by the one or more magnets of thefirst side edge includes a component in the lateral direction.
 3. Thematerial conveyance apparatus of claim 2, wherein the repulsive forceprovided by the one or more magnets of the second side edge includes acomponent in the lateral direction opposite that provided by the one ormore magnets of the first side edge.
 4. The material conveyanceapparatus of claim 1, wherein the framework further comprises a tensionmember extending between the first support arm and the second supportarm, wherein the tension member provides pushing forces between thefirst support arm and the second support arm in order to place lateraltension on the belt.
 5. The material conveyance apparatus of claim 1,wherein the first support arm is pivotable relative to the centralmember.
 6. The material conveyance apparatus of claim 5, wherein theframework further comprises a tension member extending between the firstsupport arm and the second support arm, wherein the tension memberpushes the first support arm away from the second support arm.
 7. Thematerial conveyance apparatus of claim 5, wherein the second support armis pivotable relative to the central member.
 8. The material conveyanceapparatus of claim 7, wherein the framework further comprises a tensionmember extending between the first support arm and the second supportarm, wherein the tension member pushes the first support arm away fromthe second support arm.
 9. A material conveyance apparatus comprising: abelt extending in a longitudinal direction, the belt having a first sideedge including one or more magnets and a second side edge including oneor more magnets; a framework for supporting the belt, the frameworkincluding: a first elongate support rail extending in the longitudinaldirection adjacent the first side edge of the belt; and a secondelongate support rail extending in the longitudinal direction adjacentthe second side edge of the belt; wherein the one or more magnets of thefirst side edge provide a repulsive force repelling the first side edgeaway from the first elongate support rail and provide both vertical andlateral support to the belt; and wherein the one or more magnets of thesecond side edge provide a repulsive force repelling the second sideedge away from the second elongate support rail and provide bothvertical and lateral support to the belt.
 10. The material conveyanceapparatus of claim 9, wherein the first elongate support rail includesone or more magnets, wherein the one or more magnets of the firstelongate support rail repel the one or more magnets of the first sideedge of the belt away from the first elongate support rail.
 11. Thematerial conveyance apparatus of claim 10, wherein the second elongatesupport rail includes one or more magnets, wherein the one or moremagnets of the second support rail repel the one or more magnets of thesecond side edge of the belt away from the second elongate support rail.12. The material conveyance apparatus of claim 9, wherein the frameworkfurther includes a first support arm pivotably coupled to the firstsupport rail and a second support arm pivotably coupled to the secondsupport rail.
 13. The material conveyance apparatus of claim 12, furthercomprising a first tension member coupled to the first support arm, thefirst tension member pushing the first support rail away from the secondsupport rail to keep the belt in tension.
 14. The material conveyanceapparatus of claim 13, further comprising a second tension membercoupled to the second support arm, the second tension member pushing thesecond support rail away from the first support rail to keep the belt intension.
 15. A method of supporting a belt of a conveyance apparatus,the method comprising: providing a belt having one or more magnets alonga first edge of the belt and one or more magnets along a second edge ofthe belt; providing a framework including a first support rail extendingparallel to the first edge of the belt and a second support railextending parallel to the second edge of the belt; repelling the one ormore magnets along the first edge of the belt away from the firstsupport rail both laterally and vertically, forming a gap between thefirst support rail and the one or more magnets along the first edge ofthe belt; and repelling the one or more magnets along the second edge ofthe belt away from the second support rail both laterally andvertically, forming a gap between the second support rail and the one ormore magnets along the second edge of the belt; thereby providing bothlateral and vertical support to the belt.
 16. The method of claim 15,wherein the first support rail includes one or more magnets, wherein theone or more magnets along the first edge of the belt are adapted torepel away from the one or more magnets of the first support rail. 17.The method of claim 16, wherein the second support rail includes one ormore magnets, wherein the one or more magnets along the second edge ofthe belt are adapted to repel away from the one or more magnets of thesecond support rail.
 18. A method of supporting a belt of a conveyanceapparatus, the method comprising: providing a belt having a first edgeand a second edge, wherein a lateral direction is defined between thefirst side edge and the second side edge of the belt; providing one ormore magnets along the first edge of the belt and one or more magnetsalong the second edge of the belt; providing a framework including afirst support rail and a second support rail positioned parallel to thefirst support rail and spaced from the first support rail by a distance,positioning the belt between the first support rail and the secondsupport rail such that the first edge of the belt is parallel with thefirst support rail and the second edge of the belt is parallel with thesecond support rail, wherein the lateral direction of the belt spansbetween the first support rail and the second support rail; repellingthe one or more magnets along the first edge of the belt away from thefirst support rail, forming a gap between the first support rail and theone or more magnets along the first edge of the belt; and repelling theone or more magnets along the second edge of the belt away from thesecond support rail, forming a gap between the second support rail andthe one or more magnets along the second edge of the belt; and varyingthe distance between the first support rail and the second support railto vary the tension of the belt.
 19. The method of claim 18, wherein theframework further includes a first support arm coupled to the firstsupport rail, and a second support arm coupled to the second supportrail, wherein the step of varying the distance between the first supportrail and the second support rail includes moving the first support armrelative to the second support arm.
 20. The method of claim 19, furthercomprising a tensioning member coupled to the first support arm tocontrol the tension of the belt.
 21. The method of claim 18, wherein theone or more magnets along the first edge of the belt are repelled awayfrom the first support rail in both lateral and vertical directions. 22.The method of claim 21, wherein the one or more magnets along the secondedge of the belt are repelled away from the first support rail in bothlateral and vertical directions.